cost-efficient and sustainable solutions with duplex nov 2012
DESCRIPTION
Stainless SteelTRANSCRIPT
Cost-efficient and Sustainable
Solutions with Duplex
Outokumpu Customer Seminar, Middle East, November 2012
www.outokumpu.com
2 November 2012 2
Do you know your maintenance cost?
1000 m2
Actual coating cost?
Maintenance repair of coatings?
Lost production during maintenance?
Safety issues?
Environmental issues?
Short service life?
Wouldn't be better to
eliminate the coating…
Duplex!
2 November 2012 3
Contents
1. The Duplex business case
2. Cost-efficient tank design
3. Case: Cost analysis of storage tank shell
4. Successful tank solutions in Duplex
5. Conclusions: Sustainable tank solutions in Duplex
2 November 2012 3
80 years of Duplex experience
Outokumpu is the leader of
duplex innovations:
• Avesta Steelworks in Sweden
produced the first commercial
duplex grades starting around
1930
• In more recent years the
pioneer of lean duplex
grades…
The LDX™ family!
2 November 2012 4
Autoclave in duplex 453S
for production of gunpowder.
Delivered in 1933.
Positioning of Duplex grades
An excellent combination of high strength and corrosion resistance
2 November 2012 5
600
550
500
450
400
350
300
250
200
150
Du
ple
x
Au
ste
nti
c
4307
(304L)
4404
(316L)
4436
4438
(317L)
4439
904L
254 SMO®
4565
LDX 2101®
2304
2205
2507
LDX 2404®
Corrosion Resistance, CPT typical [C]
Str
en
gth
, R
p0.2
[M
Pa
]
Hot coil
Chemical composition and properties
2 November 2012 6
Steel grade Typical chemical composition,% PRE* Rp0.2min, RT**
Outokumpu EN ASTM Cr Ni Mo N Others MPa
Duplex stainless steels
LDX 2101® 1.4162 S32101 21.5 1.5 0.3 0.22 5Mn 26 450
LDX 2404® 1.4662*** S82441 24 3.6 1.6 0.27 3Mn 34 480***
2304 1.4362 S32304 23 4.8 0.3 0.10 - 26 400
2205 1.4462 S32205 22 5.7 3.1 0.17 - 35 460
2507 1.4410 S32750 25 7 4 0.27 - 43 530
Austenitic stainless steels
4307 1.4307 304L 18.1 8.1 - - - 18 200
4404 1.4404 316L 17.2 10.1 2.1 - - 24 220
904L 1.4539 904L 20 25 4.3 - 1.5Cu 34 220
254 SMO® 1.4547 S31254 20 18 6.1 0.20 Cu 43 300
* Pitting resistance equivalent, PRE = %Cr + 3.3x%Mo + 16x%N ** Values in accordance with EN 10088 for hot rolled plate.
*** 1.4662 is not yet included in EN 10088. Rp0.2 min. value according to ASTM A240 for t >10 mm.
Characteristics of the Duplex grades
2 November 2012 7
• Higher mechanical strength than standard grades
• Good resistance to pitting and crevice corrosion
• Good weldability
• Higher fatigue resistance than standard grades
• High resistance to stress corrosion cracking and
corrosion fatigue
• Low price for pitting and crevice corrosion resistance
(price for PRE very low)
• High wear resistance
• Low thermal expansion
• High energy absorption
Duplex =
Austenitic-ferritic structure
The Duplex business case
2 November 2012 8
Improved Cost Efficiency!
Opportunity
Benefits
Excellent mechanical properties
High corrosion resistance
Good fabricability
Characteristics
Thinner gauges due to higher strength –
Weight savings!
Better durability and reduced maintenance –
Longer service life!
Cost efficient alloying (High N, low Ni) –
Cost stability!
Customer service and prefabrication –
Support and added value!
Brings multiple
sustainability
benefits!
Cost efficiency
2 November 2012 9
Cost Efficiency = Maximum Performance of the Investment
• Minimize Total Material Cost
• Minimize Total Fabrication Cost
• Minimize Total Life Cycle Cost
Total Life Cycle Cost
Material Cost
Total Initial Cost
Fabrication Cost
Operation and
Maintenance Cost
Total Life Cycle Cost
Material
Cost
Total Initial Cost
Fabrication
Cost
Operating
and
Maintenance
Cost
Successful solutions in Duplex
2 November 2012 10
The high corrosion
resistance and strength of
LDX 2404® mean it can be
used as a complement or
substitute in applications
where austenitic molother
duplex grades such as 2205
have traditionally been used.
Superior cost efficient solutions
for high strength constructions
in corrosive environments Courtesy of Kvaerner
Pressure vessels Storage tanks Desalination – Evaporators
Flexible lines
Roofing and wall panels Bridges Chemical tankers
Superior Cost Efficiency
for constructions in corrosive
environments
2 November 2012 11
Contents
1. The Duplex business case
2. Cost-efficient tank design
3. Case: Cost analysis of storage tank shell
4. Successful tank solutions in Duplex
5. Conclusions: Sustainable tank solutions in Duplex
Cost-efficient design – Utilize strength!
2 November 2012 12
Factors influencing how the strength can be utilized:
• Function: cylinder with internal pressure, plate in bending etc.
• Constraints:
• Shape (diameter, height etc.)
• Loading condition (wind loads, seismic loads, fatigue loads etc.)
• Material standards and design codes (allowable design stresses etc.)
7.8 200 655 450 2205
7.9 200 485 170 4307 (304L)
7.8 200 650 450 LDX 2101®
[x103kg/m3]
E [GPa]
Rm [MPa] Rp0.2 [MPa] Grade
Mechanical and physical properties, RT, minimum values
170 485 200 8.0 4404 (316L)
*Hot rolled plate at ambient temperature according to ASTM A 240
Utilize strength – Structural efficiency
2 November 2012 13
Pinternal >> Pexternal
Tank - base
⇒
Critical design criteria
Rp0.2
Pexternal >> Pinternal
Tank - top
⇒ E
Structural stability!
Structural instability!
P=Pressure
Utilize strength – Structural efficiency
2 November 2012 14
Critical design criteria
⇒ LDX 2101®/2205
~58
304L/316L
~21
Weight saving potential more than 50%
⇒ LDX 2101®/2205
~26 304L/316L
~25
Weight saving potential less than 3%
Rp0.2
E
2 November 2012 15
0
100
200
300
400
500
600
Proof strength, Rp0,2
API 650* EN 14015** EN 13445** ASME VIII-1****
LDX 2404™ LDX 2101® 2205 2304 4404 (316L)
Design strength at RT (MPa)
Storage tank codes Pressure vessel codes
*
®
* Design stresses in accordance with API 650, Appendix X (Duplex stainless steel), which refers further to ASTM A240.
** Design stresses in accordance with EN 14015, which refers further to EN 10088-2. Maximum design stress is limited to 260
MPa.
*** Design stresses in accordance with EN 13445, which refers further to EN 10028-7 (EAM or PMA if not included in EN 10028-7).
**** Design stresses in accordance with ASME VIII-1, which refers to ASME II-D, code cases, and ASME SA-240.
Note: LDX 2101 and LDX 2404 are pending for inclusion in EN 10088-2. They are not yet included in EN 10028-7 (EAM-0045-01
is applicable for LDX 2101, thicknesses up to and including 10 mm). ASME code case 2418-1 is applicable for LDX 2101.
ASME code case is pending for LDX 2404. LDX 2404 is not yet included in API 650 Appendix X.
Allowable design strength
Size matters – Tank shell design
2 November 2012 16
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
Storage tank D=28m,H=28m
Storage tank D=20m,H=20m
Storage tank D=14m,H=14m
Storage tank D=12m,H=12m
API650 EN14015
D
H
Potential
weight savings *
*Based on minimum allowable thicknesses for tank shell in accordance with specified design code.
Duplex – any value for smaller tanks?
2 November 2012 17
Benefits:
• Higher durability: wear, dent
(permanent deformation) resistance
• Cost efficient alloying (High N, low Ni)
for highest corrosion resistance
• High pressure tanks –
strength utilization possible
? Constraints:
• Limited strength utilization –
critical design criteria:
stiffness/buckling resistance
• Design codes: allowable design
stresses, minimum shell thickness
requirements
Fabrication of Duplex
2 November 2012 18
Welding
• Weldability of duplex is good
• Most welding methods can
be used
• Welding characteristic
deviates from austenitic steel
• Always use appropriate filler
metal and procedures
• Welding personnel must be
informed and qualified
according to the demands of
the application
Machining
• Duplex steels generally more
difficult to machine than
austenitic grades
• LDX 2101 has excellent
machinability!
Cold forming
• Higher strength of duplex
grades: Greater working forces
and spring-back during forming
• Somewhat lower ductility
(fracture elongation, A5):
Avoid sharp bend radii and
more demanding forming
techniques
Welding of Duplex
2 November 2012 19
Welding of duplex is different from welding
austenitics in terms of:
• Joint angle (larger opening for
duplex)
• Shielding gas/Purging gas
• Speed (lower for duplex)
• Filler recommendations
(overalloyed)
• Autogenous welding with TIG
• Heat input
When changing from austenitic to duplex
qualify the operators and the procedures.
2 November 2012 20
Contents
1. The Duplex business case
2. Cost-efficient tank design
3. Case: Cost analysis of storage tank shell
4. Successful tank solutions in Duplex
5. Conclusions: Sustainable tank solutions in Duplex
Case: Cost analysis of storage tank shell
2 November 2012 21
Tank height: 20 m
Tank diameter: 20 m
Volume: 6280 m3
Surface area: 1260 m2
Density of content: 1 g/ml
Temperature: 20C
Design code: API 650
Joint factor: 1
Maximum allowable design stress:
Find out more:
www.outokumpu.com
Products >>
Tools >>
4307 (304L)
Sd=145 MPa
LDX 2101®
Sd=260 MPa
A516-60 (S235)
Sd=147 MPa
A537-2 (S420)
Sd=234 MPa
Basic shell design – Structural efficiency
2 November 2012 22
Basic shell design in accordance
with API 650:
• Minimum shell thickness:
• 15 ≤ D ≤ 30 m min. td = 6 mm
• Plate width: 2000 mm
(10 shell courses H = 20 m)
• Corrosion allowance,
CA = 1.5 mm added to the
carbon steels
6.0
6.0
6.0
6.0
6.5
7.9
9.2
10.6
11.9
13.3
304L
82.7 mt
LDX 2101®
61.6 mt
S235
97.0 mt
S420
78.6 mt
-22%
+5%
+23%
Ref.
mm mm mm mm
7.5
7.5
7.5
7.5
8.0
9.3
10.6
12.0
13.3
14.6
7.5
7.5
7.5
7.5
7.5
7.5
7.5
8.1
8.9
9.8
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.0
6.7
7.4
D = 20 m
H =
20
m
td = + CA 4.9D(H-0.3)G
Sd
-26%
Ref.
Duplex improves both durability and
manufacturability
2 November 2012 23
Standards
Wider, longer and
thinner plates:
- Less joint preparation!
- Less welding!
- Shorter welding time!
14
1,28 kg/m*
4307/304L4307/304L
8
0,47 kg/m*
LDX2101®LDX2101®
~40% Thickness Reduction
~60% Weld Metal Reduction
*Filler metal consumption (FCAW) according to
The Avesta Welding Manual 2:ed 2005
Duplex grades not
difficult to weld,
but different:
- Follow welding
recommendations!
Improved fatigue, wear
and corrosion resistance:
= Longer service life!
Less corrosion – Less
maintenance compared
to coated carbon steel!
Smooth 2B
surface finish
suitable for the
food industry
available up to
6 mm!
Initial investment – ‘High’ cost level
2 November 2012 24
69
69
301
301
Internal surface treatment cost (USD/m2):
LDX 2101 304L A516-60 A537-2
22 22 180 180
External surface treatment cost (USD/m2):
LDX 2101 304L A516-60 A537-2
22 22 60 60
200
400
600
LDX 2101 304L A516-60 A537-2
x1000
USD
Material cost (USD/mt):
Based on average hot rolled coil prices per unit of
weight, 5-year-period (2005-2009).
LDX 2101 304L A516-60 A537-2
3200 3000 750 1000
Weight of plate materials (mt):
LDX 2101 304L A516-60 A537-2
61.6 -22% 82.7 +5% 97.0 +23% 78.6 ref.
117
175
207
141
Welding and assembly cost:
Based FCAW wire, typical welding and labor costs
for e.g. Northern Europe.
Wire consumption (kg):
LDX 2101 304L A516-60 A537-2
520 -37% 940 +13% 1210 +46% 830 ref.
Welding and assembly time (h)
LDX 2101 304L A516-60 A537-2
1400 -33% 2300 +10% 3000 +43% 2100 ref.
-27% -6% +14% Ref.
Higher strength – Weight savings –
Less welding – Less surface treatment:
Improved Cost Efficiency!
199 249 91 81
Initial investment – ‘Low’ cost level
2 November 2012 25
22
22
100
100
Internal surface treatment cost (USD/m2):
LDX 2101 304L A516-60 A537-2
7 7 60 60
External surface treatment cost (USD/m2):
LDX 2101 304L A516-60 A537-2
7 7 20 20
100
200
300
LDX 2101 304L A516-60 A537-2
USD x1000
Material cost (USD/mt):
Based on average hot rolled coil prices per unit of
weight, 5-year-period (2005-2009).
LDX 2101 304L A516-60 A537-2
3200 3000 750 1000
Weight of plate materials (mt):
LDX 2101 304L A516-60 A537-2
61.6 -22% 82.7 +5% 97.0 +23% 78.6 ref.
33
43
43
29
Welding and assembly cost:
Based FCAW wire, typical welding and labor costs
for e.g. China, South-East Asia.
Wire consumption (kg):
LDX 2101 304L A516-60 A537-2
520 -37% 940 +13% 1210 +46% 830 ref.
Welding and assembly time (h)
LDX 2101 304L A516-60 A537-2
1400 -33% 2300 +10% 3000 +43% 2100 ref.
+20% +49% +11% Ref.
Higher strength – Weight savings –
Less welding – Less surface treatment:
Improved Cost Efficiency!
199 249 91 81
Life cycle cost – Maintenance cost
2 November 2012 26
113
Maintenance cost
Cost analysis data:
Real interest rate: 4%
Life cycle duration: 30 yrs.
Complete recoating after 10 and 20 yrs.
Internal surface treatment cost (USD/m2):
LDX 2101 304L A537-2
- - 60
External surface treatment cost (USD/m2):
LDX 2101 4307(304L) S235 S420
- - 20
LDX 2101 304L A537-2
253 314 211
100
200
300
400
X1000
USD Initial investment cost (x1000 USD) LDX 2101 304L A537-2
253 +20% 314 +49% 211 ref. -22% -12% -18% Ref.
Note: Lost production time and
its cost at maintenance stop, as well as
final scrap value, are additional
favorable factors for stainless steel to
consider in the life cycle cost analysis.
Life cycle thinking with Duplex
2 November 2012 27
A sustainable product:
• Scrap-based production
• 100% recyclable
• Low level of metal ion release into the
environment
• High durability, longer lifetime – less
maintenance
• No need for environmentally harmful
protective coatings
• Avoid unsafe maintenance work
• Using Duplex’s strength to reduce
weight: Lower energy consumption,
lower CO2 emission levels.
2 November 2012 28
Contents
1. The Duplex business case
2. Cost-efficient tank design
3. Case: Cost analysis of storage tank shell
4. Successful tank solutions in Duplex
5. Conclusions: Sustainable tank solutions in Duplex
2 November 2012 28
Successful tank solutions in Duplex
2 November 2012 29
600
550
500
450
400
350
300
250
200
150
Du
ple
xA
us
ten
tic
43074404
4436
4438
4439
904L
254 SMO
4565
LDX 2101®
2304
2205
2507
LDX 2404®
Corrosion Resistance, CPT typical
Str
en
gth
, R
p0.2
[M
Pa
]
Hot coilMining and Minerals:
254 SMO in mix and collection
tanks for copper processing, Chile
Chemical industry:
2205 in phosphoric
acid tank, Sweden
Chemical industry:
2304 in acetic acid tank, Spain Mining and Minerals:
2507 in tanks for zinc processing, Spain Food industry:
LDX 2101 in tank farm for
edible oils, The Netherlands
Successful tank solutions in LDX 2101®
2 November 2012 30
Waste water treatment tank, Poland
Pulp and Paper liquor tank, Finland Palm oil tank farm, The Netherlands Corn silos, Hungary
Fabrication of storage tanks for honey
and edible oils etc., Spain
Wine tank park, Spain
Tank transportation, The Netherlands
Superior cost efficiency provided
with LDX 2101® for tank applications
in a variety of industries
New tank solutions with LDX 2404®
2 November 2012 31
Tank Specification:
Height = 20 m
Diameter = 22 m
Content density = 1,0 kg/dm3
Temperature = 20°C
Design code = API 650
Joint efficiency = 0,85
Allowable design stress:
• 4404 (316L) = 145 MPa
• 2205 (S32205) = 262 MPa
• LDX 2404® (S82441) = 296* MPa
* Not yet included in API 650 Appendix X.
The design stress shall be 0.4Rm.
Potential weight
saving as a substitute for 4404 :
~40%
20
18
16
14
12
10
8
6
4
2
[m]
Required thickness
Duplex LDX 2404®
72 tons
Required thickness
Duplex 2205
75 tons
Required thickness
Austenitic 4404
117 tons
Cr% Ni% Mo% Mn% N%
24 3.6 1.6 3.0 0.27
Our customers…
• Were enthusiastic about the potential of
duplex as a construction material
• Required corrosion resistance beyond
316
• Were not entirely satisfied with the
mechanical strength of 2304
• Could not fully benefit from the alloy
content of 2205
... were the starting point for LDX 2404®
2 November 2012 32
Contents
1. The Duplex business case
2. Cost-efficient tank design
3. Case: Cost analysis of storage tank shell
4. Successful tank solutions in Duplex
5. Conclusions: Sustainable tank solutions in Duplex
2 November 2012 32
2 November 2012 33
Conclusions: Cost-efficient and
sustainable solutions in Duplex
2 November 2012 33
• Enhanced Structural Efficiency due to higher allowable design strength –
No corrosion allowance
– Weight savings!
• Enhanced Durability due to higher corrosion and mechanical
resistance – Less maintenance – Less lost
production time – less environmental impact
– Longer and safer service life!
• Enhanced Manufacturability with good weldability and thinner gauges –
Less joint preparation and less welding
– Shorter fabrication time!
• Improved Cost Efficiency
and Sustainability!
Thank You!
www.outokumpu.com